Help! My Subaru Gas Cap is Stuck – Quick Fixes and Solutions

Ever pulled up to a gas station only to find your Subaru’s gas cap door won’t budge? It’s frustrating, especially when you’re running on fumes. Whether it’s frozen shut in winter or the release mechanism is playing hard to get, a stuck gas cap can throw a wrench in your day. I’ll walk you through the most effective solutions to get you back on the road quickly.

Why Your Subaru Gas Cap Gets Stuck

Before diving into solutions, it helps to understand why your Subaru’s gas cap might be stuck in the first place. The cause typically falls into one of these categories:

• Lock system issues: Newer Subarus connect the fuel door to your central locking system
• Release mechanism problems: Older models with interior fuel door levers can have stuck cables or springs
• Weather-related issues: Ice and snow are common culprits in winter months
• Mechanical failures: Broken springs, damaged latches, or worn-out components

Let’s tackle each of these problems with specific solutions.

Different Gas Cap Systems in Subaru Models

Your fix depends largely on which Subaru you drive, as the fuel door systems have changed over the years.

Newer Subaru Models (2019+)

If you drive a newer Subaru like a:

• 2019+ Forester
• 2020+ Outback
• 2023+ Ascent
• 2023+ BRZ
• 2024+ Impreza or Crosstrek

Your fuel door is designed differently than older models. These newer vehicles connect the fuel door to your central locking system, eliminating the need for an interior release lever.

The Simple Fix: Unlock your car! When your doors are locked, the fuel door is also locked. Just press the unlock button on your key fob or door panel, then press the fuel door, and it should pop open.

One Subaru owner discovered this the hard way, sharing on Reddit: “After 15 minutes of frustrated pushing and pulling at the gas station, I accidentally hit my unlock button and the door popped right open. I felt pretty silly!”

Older Subaru Models with Release Levers

If your Subaru has an interior fuel door release lever (typically on the driver’s side floor), you’ll need different approaches.

Quick Fixes for Stuck Gas Caps

The Two-Person Method

This is often the most effective solution for older Subarus with release levers:

1. Have a friend pull and hold the fuel door release lever inside the car
2. While they’re holding it, go to the fuel door and gently push on it
3. As they pull the lever, try to pry open the door with your fingers

Many Subaru owners report this works when nothing else will.

The Solo Method

No helper available? Try this:

1. Find something to prop the lever with (a wallet, screwdriver, or even your seatbelt)
2. Wedge it to hold the release lever in the open position
3. Quickly go to the fuel door and work it open before the prop slips

A Subaru Outback owner shared: “I wedged my wallet under the release lever, ran to the back, and gave the door a firm push. Worked like a charm after struggling for 20 minutes!”

Cold Weather Solutions for Frozen Gas Doors

Winter can be especially problematic for Subaru gas doors. Here’s how to deal with ice:

The Warm Water Trick

1. Fill a water bottle with warm (not boiling) water
2. Pour it over the edges of the fuel door
3. Try opening the door immediately before it refreezes
4. Dry the area thoroughly afterward to prevent more freezing

The Tapping Technique

Sometimes, breaking up the ice is all you need:

1. Give the fuel door a few gentle taps with your fist
2. Try the release lever again
3. Repeat the tapping process if needed

One Forester owner noted that three firm taps around the edges freed her frozen gas door when nothing else worked.

The Credit Card Method

For stubborn ice around the edges:

1. Take a credit card (not your favorite one!)
2. Wrap it in a microfiber cloth to prevent scratches
3. Carefully run it along the edges of the fuel door to break the ice seal
4. Try the release lever again

Prevention is Better Than Cure

To avoid winter freezing problems:

1. Apply a thin layer of WD-40 to the latch mechanism before winter
2. Dry the fuel door area thoroughly after washing your car
3. Consider applying a thin coat of petroleum jelly around the door seals

Emergency Manual Release Methods

Subaru engineers thought ahead and included emergency releases for when the normal mechanisms fail.

For 2019+ Models

Newer Subarus have a hidden emergency fuel door release you might not know about:

1. Open your rear hatch/trunk
2. Look for a small rectangular cover on the right side of the cargo area
3. Remove this cover (you might need the included screwdriver tool)
4. Find the orange plastic cable with a handle
5. Gently pull the orange release cable

This emergency release bypasses the electronic locking system and can be a lifesaver when you’re stranded.

For Older Models

Check your trunk area for a manual release cable, which is typically:

• Located behind the trunk carpet liner
• Colored green or yellow for easy identification
• Accessible without tools

Fixing Mechanical Issues With Your Gas Door

When the problem is mechanical rather than circumstantial, you might need to address the actual components.

Spring Problems

If your fuel door doesn’t pop open properly, the issue may be with the spring mechanism:

DIY Fix:

1. Carefully examine the spring mechanism (usually visible when you get the door open)
2. If it looks intact but weak, you can try gently bending it to increase tension
3. Test the door several times to see if it pops open properly

Replacement Option:
If the spring is broken, you’ll need to replace the fuel door spring assembly. These parts typically cost between $31-65 depending on your model.

The part number for many Subaru fuel door mechanisms is 57310xc00a, which you can order from your dealer or find online.

Cable and Lever Issues

Sometimes the problem lies with the release cable or lever:

1. Inspect the cable pathway for kinks or obstructions
2. Clean the lever mechanism to remove dirt and debris
3. Apply a small amount of silicone-based lubricant to moving parts
4. Avoid petroleum-based lubricants which can damage plastic components

A Subaru XV owner shared that simply cleaning the accumulated gunk from their floor-mounted lever solved their persistent issues.

Professional Repair Options

When DIY methods fail, it might be time to call in professional help:

Dealer Service

Your Subaru dealer has the proper tools and parts to fix stubborn gas door issues. Expect to pay:

• $100-150 for labor (typically 1 hour)
• $31-65 for parts if replacement is needed
• Potentially more if there’s damage to the surrounding panel

Independent Mechanics

A trusted independent mechanic can often handle this repair at a lower cost:

• Usually 30-50% less than dealer prices
• May have to order the parts, extending repair time
• Can be just as effective as dealer service

Preventative Maintenance Tips

To avoid future gas cap frustrations, add these to your maintenance routine:

Regular Cleaning

1. Wipe down the fuel door area during each car wash
2. Pay special attention to the release lever area inside the car
3. Remove debris from the door edges and hinge points

Periodic Lubrication

Every 6 months or before winter:

1. Apply a thin coat of Teflon lubricant to the fuel door hinge
2. Use a silicone-based spray for the latch mechanism
3. Ensure the release cable moves freely

Winter Preparation

Before the cold hits:

1. Apply a water-displacing lubricant to moving parts
2. Consider using a lock de-icer around the door edges
3. Keep a small bottle of de-icer in your car for emergencies

Comparison of Common Solutions

Special Situations: When Standard Fixes Don’t Work

Electrical System Issues

For newer Subarus with electronic locking fuel doors, electrical problems might be at play:

1. Check your car’s fuses (consult your owner’s manual for location)
2. Look for the fuel door actuator fuse specifically
3. Replace if blown, but if it blows again, there may be a short circuit

Collision Damage

If your car has been in an accident, even a minor one:

1. Examine the fuel door area for signs of misalignment
2. Check if the surrounding panel is bent or damaged
3. This may require body shop attention to straighten the panel

Complete Mechanism Failure

In rare cases, the entire mechanism needs replacement:

1. This is more common in high-mileage vehicles
2. Look for the part number in your manual or ask your dealer
3. Complete replacement kits typically cost $65-120 depending on your model

Remember, a stuck gas cap might seem like a minor annoyance, but addressing it promptly prevents further damage and saves you from the frustration of being stranded at a gas station with an empty tank. With these tips, you’ll be back to hassle-free fill-ups in no time!